Surface production operations. Volume III, Facility piping and pipeline systems

1113 Pages·2016·91.83 MB·English

Volume III
Surface Production Operations
Surface Production
Operations
Facility Piping and Pipeline Systems
Volume III
MAURICE STEWART
Principal, Stewart Training and
Consulting LLC, McLean, Virginia, USA
AMSTERDAM (cid:129) BOSTON (cid:129) HEIDELBERG (cid:129) LONDON
NEW YORK (cid:129) OXFORD (cid:129) PARIS (cid:129) SAN DIEGO
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Dedicated tomywife Dyah,
myson Chad,
and inmemory ofmyparents Mauriceand BessieStewart.
Preface
WhenIwasayoungengineer,Iwasoftenconfrontedwithaproblemthatwasnewto
me.Iwouldoftenaskseniorengineersorsupervisorsforadviceonhowtosolvethe
problem and they would advise me to “check Project ABC” or they would go to a
“hidden” folder in a locked drawer and pull out a detailed calculation. Often
Iwoulddigthroughstacksoffilesordrawingsorgothroughcalculationsonlytofind
thattheproblemsIhadwerenotthesame,orwhattheyhadimaginedasanexisting
solutionwasnotapplicable.Nothingwasonpaperthatcouldbeappliedtotheproblem
athand.Thesesortofproblemsappliednotonlytopipingdesignbutalsotoallaspects
of facilitiesengineering.
Asateacheroffacilitypipingandpipelinesystems,Ispentalotoftimelookingfor
answers in reference materials, only to discover that many texts were silent on the
topicunderinvestigation.Irealizedthatthereisnosinglesourcethatcouldbeused
asatextinthisfield.Thus,Iwasforcedtoreproducepagesfromcatalogs,reports,and
projectsthatIhaddonetoprovidestudentswiththebasicinformationtheyneededto
understandthelecturersandcarryouttheirassignments.Moreimportantly,themate-
rialthatdidexistusuallycontainednomographs,charts,andrulesofthumbthatdid
not refer to the basic theories and underlying assumptions upon which they were
based.AlthoughVolume3buildsupontheinformationthatwaspresentedinSurface
ProductionOperations,Volume1:DesignofOil-HandlingSystemsandFacilitiesand
Volume2:DesignofGas-HandlingSystemsandFacilities,itdoespresentthebasic
concepts and techniques necessary to select, specify, size, construct, operate, and
repair facility piping andonshore andoffshore pipeline systems.
Formanyyears,Iwantedtocompilemythoughtsaboutpipingdesignintoanorga-
nizedtextbook.Itriedtoorganizethistextinalogicalmannerandmaketheinforma-
tionreadableandeasytoaccess.Thistextisintendedtobe“practical”guideonthe
design of facility piping and pipeline systems. It is not intended to be a “one-stop”
comprehensivetextdiscussingeveryaspectofprocesspipingorpipelineengineering.
Itriedtohighlighttheitemsafacilityengineerwillmostlikelyencounter,ratherthan
toattempttowriteanencyclopedicvolume.Forexample,thereismuchinformationin
ASMEB31.3;Ihaveonlytouchedontheportionsthedesignermightencounterina
“typical”facilitypipingjob.Throughoutthepreparationofthetext,Itriedtostrikea
balancebetweentheoryandapplication.Examplesaredistributedthroughoutthetext
toenhance the principles covered.
The text isdivided intothreeparts:
Thefirstofwhichisdevotedalmostentirelytopipingstandards,codes,andrecommended
practices;materialsofconstruction;pipingsystemcomponents,fittings,valves,andappur-
tenances; engineering drawings, data sheets, and symbols; fluid flow and pressure drop
determination; choosing a line size and wall thickness; relief, vent, and flare disposal
xii Preface
systems;pipingsystemdesignlayout,supports,pipingvessels,andequipment;andpiping
expansionandflexibility.
Thesecondpartdeals withonshorepipeline systems,pressuretestingandnondestructive
examination,pipelinepigging,andpipelineoperations.
Thethirdpartconsistsoftechnicaldataincludedintheappendix.
Throughoutthistext,IhaveattemptedtoconcentrateonwhatIperceivetobemodern
andcommonpractices.Ihavebeenpersonallybeeninvolvedinthedesign,selection,
construction,andrepairoffacilitypipingandpipelinesystemsthroughouttheworld,
orhavepeopleinmyorganizationwhohavedoneso.Undoubtedly,Iaminfluencedby
my own experience and prejudices. I apologize if I left something out or have
expressed opinions about certain equipment or procedures that differ from your
own.Ihavelearnedmuchfrommystudents’commentsaboutsuchmattersandwould
appreciate receivingyour input for future revisions/editions.
Maurice I.Stewart Jr. PE PhD
McLean, VA,USA
Acknowledgments
This book is essentially the summary of the knowledge accumulated by the author
through 40 plus years of practice as a facilities engineer in the upstream oil and
gasindustry.Iwouldliketotakethisopportunitytoexpressmyappreciationandgrat-
itudetomymanyfriends,colleagues,andmentorsforprovidinginvaluablelearning
opportunities.
IwouldthankKenE.Arnold,PE,theseniorcoauthorofthefirsttwovolumesof
SurfaceProductionOperationsseries.MuchoftheinformationinVolume3wasorig-
inallycontainedinVolumes 1and2.Kenisalsoresponsibleforencouragingmeto
teach 2-day courses for the Society of Petroleum Engineers on Surface Production
Operations,which,inturn,leadtothefirsttwovolumesoftheseries.WithoutKen’s
expertcontributions, Volumes 1 and 2wouldnot have been possible.
IwouldliketothankStanton“Stan”Marsland,PE,withSDMarsland&Partners
Ltd, for his valuable input on Chapter 11—Pipeline Systems and Chapter 14—
Pipeline Operations. Stan’s knowledge and over 45years working experience in all
aspectson onshore and offshore pipelines throughoutthe world is second tonone.
I want to thank John Joseph Crump JD, PE for his critique and input on
Chapter2—PipingStandards,Codes,andRecommendedPracticesandproofreading
ofChapter6—FluidFlowandPressureDropandChapter7—ChoosingaLineSize
andWallThickness.Johnmadesureallreferencestothevariouscodeswerecorrect
andaccurate.Inaddition,heoftenprovidedbetterwaysonhowtopresentmaterialsin
the manuscript.
Iwanttothankmyinternationalbusinesspartnersandveryclosefriends—Jamin
Djuang, Managing Director of PT Loka Datamas Indah (LDI Training); Chang
Choon Kiang “CK,” Managing Director of Professional Training Southeast Asia
(PTSEA); and Clement “Clem” Nwogbo, Managing Director of Resource Plus.
Together, forover 25years,we have provided training toover50,000professionals
inevery oil-producingregionof the world.
I also want to thank my colleagues on the numerous API Committees, in which
Iservedasacommitteemember,withwhomIhavehadmanyinterestingdiscussions,
andthethousandsofstudentsinthecourses.Ihavetaughtthathave,attimes,asked
difficultquestions,thathavegreatlyenrichedthisbook.Withouttheirvaluableinput,
Volumes1, 2, or3 would nothave been possible.
Lastbutcertainlynotleast,Iwanttothankmygoodfriendandcolleague—Heri
Wibowo,who notonly preparedallillustrations, tables photos,andfigures butalso
tookmypoorlytypedrawmanuscriptandtransformeditintoaformatsuitabletosub-
mittothepublisher.Heritooklooselydrawnsketchesorconcepts,oftensketchedon
the back on a Starbuck’s napkin or on the back of airline e-ticket, and transformed
xiv Acknowledgments
themintoaverydetaileddrawingillustratingtheexactpointsIwastryingtogetacross
in the text.
Icannotconcludewithoutthankingthenumerousmanufacturersandassociations
thatofferedtheuseoftechnicaldata,information,orartwork.Ithankedthemthrough-
out the textwhen using their materialbut those deservingspecial thanks are:
l AmericanPetroleumInstitute
l AmericanSocietyofMechanicalEngineers
l AmericanWeldingSociety
l ApacheOffshore
l BonneyForgeCorporation
l BritishPetroleum
l CharlesWheatleyCompany
l ChevronWorldwide
l C.MorrisCompany
l CraneEnergyFlowSolutions
l DanielsIndustries
l DresserIndustries
l EvertiteCompany
l ExxonMobilWorldwide
l Flexitalic
l GarlocCompany
l GraylockCompany
l GruvagripCompany
l InternationalStandardsOrganization(ISO)
l JandeNul
l LamonsCompany
l Medco
l Pertimina
l PetroleumAuthorityofThailand(PTTEP)
l Petronas
l Orbit,Inc.
l RipWeaver
l RockwellInternational
l SEMAC
l ShellWorldwide
l Smith-BlairCompany
l Technip
l TotalE&PWorldwide
l TubularExchangerManufacturer’sAssociation(TEMA)
l VictaulicCompany
l TubeTurn
l WellstreamInternational
l WKM
My sincere apologies toanyone Imay have overlooked.
Maurice I.Stewart Jr. PE PhD
StewartTraining andConsulting (STC),LLC
1
Overview of facility piping and
pipeline systems
1.1 Overview
Afterwellsaresuccessfullydrilledandcompleted,thefluidproducedmustbetrans-
ported to a facility where it separated into oil, water, and gas; conditioned to meet
process input requirements; treated to remove impurities such as H S, CO , H O,
2 2 2
and solids; processed into specific end products, for example, NGL and LPG; mea-
sured;andrefinedorstoredforeventualsales.Figure1.1isasimplifiedblockdiagram
thatillustratesthebasic“wellheadtosales”concept.Thediagrambeginswithwell-
headchokewhichisusedtocontroltherateofflowfromeachwell.Thefluidfromthe
welltravelsthroughaflowlinetotheproductionfacilitywherethefluidisseparated,
conditioned, treated, processed, measured, refined, or stored. Detailed discussions
concerning oil, gas and water handling, conditioning, and processing facilities are
coveredinVolumes1and2;pumps,compressors,anddriversarecoveredinVolume
4; and sizing, selecting, designing, installing, and operating process equipment-
pressure vessels,heat exchangers,and storage tanks are covered inVolume 5.
Volume1:DesignofOil-HandlingSystemsandFacilitiesandVolume2:Designof
Gas-HandlingSystemsandFacilitiesoftheSurfaceProductionOperationsseriespre-
sentthebasicconceptsandtechniquesnecessarytoselect,specify,size,operate,and
troubleshootoil,waterandgashandling,conditioning,andprocessingfacilities.Vol-
ume3:FacilityPipingandPipelineSystemsbuildsupontheinformationthatispres-
entedin Volumes 1 and 2.
Chapter 1 provides an introduction of piping design and projects, types and
functions of facility and pipeline systems and facility design considerations. The
Chapter also reviews a typical facility piping design project and reviews specific
considerations related to offshore operations. Chapter 2 reviews piping standards,
codes,andrecommendedpracticesforbothfacilitypipingandpipelinesystems.This
chapter discusses both ASME and other international piping standards. Chapter 3
reviewsASMEPipingCodematerialrequirementsforferrous,nonferrous,andplastic
pipe.High-andlow-temperatureservicematerialrequirementsandinsulatingmate-
rialsarealsodiscussed.Chapter4coverspipingsystemcomponentssuchasthevarious
methodsofconnectingpipe,expansionjointsandflexiblepiping,fittings,valves,valve
specifications,andpressureratings.Engineeringdrawings,datasheets,pipingdrafting
symbols,andflowplanarrangementarediscussedinChapter5.Chapter6discusses
fluidflowandpressuredropdetermination,whileChapter7discussestheparameters
thatneedtobeconsideredwhenchoosingalinesizeandcoderequirementswhendeter-
miningthewallthickness.Chapter8coversreliefdeviceselection,sizing,installation
andrelief, andventandflaredisposalsystemdesign.Facility pipingsystemdesign,
piping details, layout, supports, and vessel and piping equipment are covered in
SurfaceProductionOperations.http://dx.doi.org/10.1016/B978-1-85617-808-2.00001-8
Copyright©2016ElsevierInc.Allrightsreserved.
2 SurfaceProductionOperations
Figure1.1 Blockdiagramof“wellheadtosales”concept.
Chapter 9. Chapter 10 discusses expansion piping and flexibility considerations.
Chapter 11 reviews all phases of both onshore and offshore pipeline engineering,
pipelinemechanicaldesign,pipelineconstructionconsiderations,anduniqueoffshore
pipelineconsiderations.Chapter12discussesfacilitypipingandpipelinesystempres-
sure testing and nondestruction examination requirements. Chapter 13 discusses
reasonsforpiggingapipeline,designingapipelineforpigging,pigtrapsandpigging
stations,pigtypesanduses,andin-lineinspectiontools.Pipelineoperations,integrity
assessment,andpipelineemergenciesandrepairsarecoveredinChapter14.
1.2 Introduction to piping design and projects
Therearemanycommercialandindustrialfluidhandlingapplicationsconveyingfluid
from one location toanother. At the outset, one must askthe following questions:
l Whatfluidsmustbeconveyed?
(cid:1) Oil,water,gas,steam,air,N ,andothers
2
(cid:1) Aresolidspresent?
(cid:1) Whataretherates,pressures,temperatures,andviscosities?
l Whatdowewanttodowiththefluid?
(cid:1) MovefrompointAtopointB
(cid:1) Howfar?Whataretheelevationdifferences/conditions?
l Howwillwedowhat?Construction
(cid:1) What“piping?”Thereisabroadspectrumofgoodsavailable.
▪
Whattypeofpipeisrequired?
l Note:pipingvs.tubing—standardvs.nonstandardsizes
– Nominalpipeside(NPS)¼pipeOD
– PipeIDvarieswithwallthickness
▪
Whatvalvesandfittingsarerequired?
▪
Ispumping/compressionrequired?
▪
Isheating/coolingrequired?
▪
Whatprocessequipmentisneeded?